|Publication number||US7496421 B2|
|Application number||US 11/446,639|
|Publication date||Feb 24, 2009|
|Filing date||Nov 26, 2004|
|Priority date||Dec 5, 2003|
|Also published as||CN1890410A, CN1890410B, EP1689918A1, EP1689918B1, US20070027565, WO2005054551A1|
|Publication number||11446639, 446639, US 7496421 B2, US 7496421B2, US-B2-7496421, US7496421 B2, US7496421B2|
|Inventors||Reinhard Mühlenmeister, Jörg Gross, Dirk Seulen|
|Original Assignee||Saurer Gmbh & Co. Kg|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (22), Classifications (14), Legal Events (3)|
|External Links: USPTO, USPTO Assignment, Espacenet|
The present application is a continuation of International Application No. PCT/EP2004/013420, filed Nov. 26, 2004, and which designates the United States. The disclosure of the referenced application is incorporated herein by reference.
The invention relates to a method for order control in a production process for a fiber product, and to an apparatus for executing the method. The production of fiber products is substantially determined by the quality standards that the fiber product is to possess. Irrespective of whether the fiber product is a single fiber or a fabric, certain application-specific properties are required. Thus, for example, U.S. Pat. No. 5,469,149 (EP 0 580 071 A2) describes the production of a synthetic fiber in which the respectively produced quality of the fiber is monitored continuously during the process. In this case, in the event of deviations, a selective method modification can be made in the production process. In this case, the production process is usually monitored and controlled from a plant controller.
In practice, the fiber products that are to be produced are determined by individual production orders. Each production lot of a fiber product is thus based on a production order. In the case of the processing of a plurality of production orders, the problem arises, particularly in the process for the production of fiber products, that, due to the complex processing steps for the production of the fiber product, a multiplicity of parameters results in unavoidable production process malfunctions, due to fluctuating quality of the fiber product or process interruptions. Thus, for example, in the case of a process for the production of textured yarns, in which a fed synthetic yarn is stretched and crimped, the fiber product is divided into quality levels A, B and C. Thus, for example, a production order having as a target standard a certain product quantity of the quality A could only be produced as efficiently as possible if, during the production process, the quality levels B and C are immaterial or do not arise at all. This cannot be realized, however, since a spool containing the crimped yarn is already assessed as being of B quality if, for example, there is contained within the spool a thread knot resulting from the transition from a supply spool to a reserve spool. Consequently, planning for the purpose of processing a plurality of successive production orders is scarcely possible, or is possible only with great effort.
Accordingly, an object of the invention is to create both a method for order control in a production process for a fiber product, and an apparatus for executing the method, with which planning for the purpose of executing production orders is possible.
A further aim of the invention is to monitor the production process in respect of the underlying production order.
The present invention achieves the above objectives and others by providing a method and apparatus for order control in a production process for a fiber product.
In one embodiment, the present invention provides a method that comprises providing and further processing at least one primary product to form the fiber product, performing individual processing steps of the further processing by machines, determining the course of the production process by a target standard of a production order, recording an actual status of the production process, performing an actual/target evaluation between a target standard predefined by the production order and the actual status of the production process, and displaying a deviation from the target standard. In another embodiment, the actual status of the production process is determined by a partial quantity of fiber product finished per unit of time, and an order-related actual value relating to the fiber product is calculated from the partial quantity of fiber product and a differential value is produced from the actual/target evaluation, wherein at least one of a product quantity or a production time for the predefined production order is determined by the target standard. In yet another embodiment, the actual value is calculated from unit of time, the partial quantity of fiber product and the product quantity, wherein an actual/target comparison results in a production time difference as a differential value. In yet another embodiment, the actual value is calculated from the partial quantity of fiber product, the unit of time and the production time, wherein the actual/target comparison results in a product quantity difference as a differential value. In yet another embodiment, the order-related target standard is entered manually via at least one of an operating unit or an ERP control unit. In yet another embodiment, the differential value is displayed by at least one of a display on the operating unit or a tracking system on the ERP control unit. In yet another embodiment, a counter-check is compiled between the target standard and the differential value in relation to a plurality of subsequent production orders, and a processing plan is derived from the counter-check. In yet another embodiment, in a case of non-fulfillment of the target standard, the target standard is modified, and a new processing plan is compiled from a renewed actual/target evaluation. In yet another embodiment, one or more status variables are recorded in relation to the fiber product or the machines executing the processing steps, and the partial quantity of fiber product is determined by means of the status variables. In yet another embodiment, a plurality of target standards of a plurality of production orders are defined, the target standards and the actual value are counter-checked according to a planning algorithm, and the provision of primary products for the subsequent orders is initiated in dependence on the counter-checking. In yet another embodiment, the target standard is complemented by specifications relating to product properties and product qualities.
Another embodiment of the present invention provides an apparatus that comprises a production plant for a fiber product produced from at least one primary product, consisting of a plurality of machines, and having a plant control unit which is connected to the machines via a control and monitoring network, wherein a master planning control unit is provided for performing an actual/target evaluation between a target standard predefined by a production order and an actual status of the production process, the planning control unit being coupled to the plant control unit via a data connection. In yet another embodiment, the plant control unit has a means by which a partial quantity of fiber product finished per unit of time can be determined. In yet another embodiment, the planning control unit has an interface for the connection of at least one of a manual operating unit or an ERP control unit, through which the target standard of the production order can be placed. In yet another embodiment, the master planning control unit has a means for generating a differential value which results from the actual/target evaluation between the target standard predefined by the production order and the actual status of the production process. In yet another embodiment, the master planning control unit has further means for determining a processing plan with specifications for the provision of the primary product and a time sequence for the further processing. In yet another embodiment, the planning control unit is connected to an output unit for visual display of data or processing plans. In yet another embodiment, the output unit is combined with at least one of the operating unit or the ERP control unit.
The invention is distinguished at least by the fact that an intelligent connection is created between the business processes and the production processes. Thus, as soon as new production orders are placed within the business process, the instantaneous situation in the production process can be included. For this purpose, according to the invention, an actual/target evaluation is performed between the target standard predefined by a production order for the production of a fiber product and the respective actual status of the production process that has been initiated on the basis of the production order. In this case, a deviation from the target standard is displayed, so that both the production order presently in the production process and subsequent production orders can be adapted.
For the purpose of executing the method according to the invention, the apparatus according to the invention has a master planning control unit, by which the actual/target evaluation can be performed between the target standard predefined by a production order and an actual status of the production process. In this case, the planning control unit is linked to the plant control unit via a data connection, so that the data necessary for determining the actual status are available to the planning control unit. The planning control unit renders possible automated planning in the production of a fiber product. A fiber product may be both individual synthetic fibers or natural fibers and primary products of these fibers, or flat end-products made from these fibers, such as, for example, woven fabric, knitted fabric or braids.
In the case of a particularly advantageous method variant, it is proposed that the actual status of the production process be determined by a partial quantity of fiber product finished per unit of time, and that an order-related actual value relating to the fiber product be calculated from the partial quantity of fiber product and a differential value be produced from the actual/target evaluation, a product quantity and/or a production time for the predefined production order being determined by the target standard. Thus, with the use of few parameters, it is already possible to effect control and planning of the production order at an early point in time. The unit of time taken as a basis for the partial quantity of fiber product could be predefined in coordination with the production time, in hours, days, weeks or months. In this case, as the production process progresses, the respective cumulatively produced partial quantity of fiber product can be determined after each unit of time, and constitute the basis for calculation of the actual value.
For the purpose of executing this method variant, an advantageous development of the apparatus comprises, at least in the plant control unit, a means by which a partial quantity of fiber product finished per unit of time can be determined. This means can advantageously be constituted by a computation module which can perform an evaluation of the continuously recorded status variables transmitted to the plant control unit. In the simplest case, for example, in a melt-spinning process a weight check on the finished wound spools could be recorded as status variables, and added up in the computation module as a partial quantity of fiber product per predefined unit of time.
It is also possible, however, for the planning control unit to have means which determine the required partial quantities of fiber product directly from the status variables and perform an actual-value calculation.
Depending on the target standard, the differential value resulting from the actual/target evaluation may advantageously be indicated as a production time difference or, alternatively, as a product quantity difference. If it is essential that the product quantity predefined by the target standard be achieved in order to fulfil the production order, the actual value is calculated from the time unit, the partial quantity of fiber product and the product quantity. The actual value thus represents an estimated production completion time which, in the actual/target comparison with the predefined production time, results in a production time difference. This determined production time difference must therefore be taken into account in the planning relating to the completion of the production order, and at the start of subsequent production orders.
If it is essential that the production time predefined by the target standard be achieved due to particularly urgent subsequent orders, the differential value could be indicated as a product quantity difference. For this, the actual value is calculated from the partial quantity of fiber product, the unit of time and the production time. The actual value thus represents an estimated product quantity that can be produced during the production time. The actual/target comparison thus results in a product quantity difference on which the production order must be based.
In the case of simple production processes and plants, the order-related target standards can advantageously be entered manually, via an operating unit. In practice, however, ERP (Enterprise Resource Planning) control units are normally used for controlling the business processes. It is thus particularly advantageous if the target standards can be directly automated and forwarded at the business process level when a production order is placed. Entering of the order-related target standard by means of the ERP control unit is thus particularly advantageous.
For the purpose of executing the method variant, a preferred development of the apparatus is designed in such a way that the planning control unit has an interface for the connection of a manual operating unit and/or an interface for the connection of an ERP control unit. A counter-check between the calculated actual values and the target standard can thus be performed at any time in the planning control unit.
In order that the deviation from the target standard can be continuously taken into account in a plan, the differential value can be displayed either by a display on the operating unit or, advantageously, by a tracking system on the ERP control unit. In the latter case, the effects on subsequent production orders can thus advantageously be taken into account at the same time, in an automated manner, in the ERP control unit, so that the business processes are updated in each case.
For this, an advantageous development of the apparatus comprises, within the planning control unit, a means for generating a differential value. Assuming that the calculated actual value and the target standard have the same basis, the differential value can already be calculated by means of a simple comparison module. The differential value can then be forwarded to the ERP control unit or to an operating unit via the interfaces of the planning control unit. The differential value could then result in the initiation of a modification of the target standard of the production order then being processed or a modification of the target standard of the subsequent production orders.
Basically, such subsequent production orders can also be entered directly in the planning control unit which, following counter-checking between the target standard and the differential value, generates a processing plan matched to the subsequent orders. Such a processing plan might be entered in the ERP control unit, for example, to allow detailed planning. This advantageously also creates the possibility of countering an unacceptable deviation in the context of the business processes, by modifying the target standard of the production order currently being processed or that of the subsequent production orders. The renewed actual/target evaluation thus results in a new processing plan which can be matched, within the business process level, to master standards.
The development of the apparatus in which the planning control unit comprises a means for determining a processing plan is therefore particularly advantageous for creating proposals for the further processing of the production orders. In particular, it provides for control of the provision of the primary products that are processed in the production process for the fiber product. The inclusion in the business processes of the processing plans generated by the planning control unit permits a high degree of flexibility in respect of the execution and completion of a multiplicity of production orders. In this case, the production process can also be divided into a plurality of sub-processes running independently of one another.
Due to the complex production processes, the fiber product to be produced is affected by a multiplicity of machines and product parameters. Thus, for example, a thread breakage within a high-speed spinning process results in production being interrupted at a spinning head. Since, at the time of the thread breakage, the wound spools do not have the required spool weight or spool diameter, in the determination of the partial quantities of the fiber product these spools might, for example, be considered to be only of C quality. In order that a reference partial quantity of fiber product can nevertheless be determined for the production order, further status variables are required, such as the fiber quality. The method variants in which one or more status variables are recorded in relation to the fiber product and/or the machine executing the processing steps are therefore particularly suitable for permitting the execution of an automated plan in the case of complex production processes. For this, the reference partial quantity of fiber product is determined by means of the status variables.
In order to achieve as full a utilization as possible of the production plant, use is made of the method variant in which, from a plurality of target standards of a plurality of production orders, continuous counter-checking with the calculated actual values is performed and, in this case, the provision of primary products for the subsequent production orders is initiated in dependence on the counterchecking. In this case, particular planning algorithms can be predefined through which, for example, priorities can be set.
Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
Both the method for order control according to the invention and the apparatus according to the invention for execution of the method are described more fully in
In the production process, a multiplicity of threads of a thermoplastic material are spun and wound up to form spools. For this, the thermoplastic material is previously conditioned in a granulate preparation system 1. The granulate preparation system 1 comprises, in essence, both a drier 2, having a heating system 3, and a metering system 4. A machine controller 5.1 is provided to control the granulate preparation system 1. The measured dried granulate is supplied to a melt preparation system 6. The melt preparation system 6 consists, in essence, of an extruder 7 to which the granulate is supplied via a filler neck 8. Within the extruder 7 there is a driven extruder screw, so that the granulated is melted and discharged via a melt line 9 at the outlet of the extruder 7. The melt preparation system 6 is monitored and controlled via the machine controller 5.2.
A spinning apparatus 10, a treatment device 15 and a winding device 17 are provided for the melt-spinning, treatment and winding of the threads. The spinning apparatus 10, in detail, comprises a multiplicity of spinning pumps 11 which supply the melt to a multiplicity of spinning heads 12. Each of the spinning heads 12 comprises a multiplicity of spinning nozzles, only one spinning nozzle per spinning head being shown in
In this exemplary embodiment, the treatment apparatus 15 consists of two roller units 16.1 and 16.2, which stretch the threads.
The winding device 17 comprises, for each spinning head, at least one spool spindle 18, on the circumference of which a plurality of spools 19 are formed simultaneously. Each thread 20 is thus wound up to form respectively one spool 19.
For each spinning head, the spinning apparatus 10, the treatment apparatus 15 and the winding device 17 are monitored and controlled by a spinning-head controller 14. In this case, the majority of the spinning-head controllers 14 are coupled to a master machine controller 5.3 via a bus system.
The machine controllers 5.1, 5.2 and 5.3 are connected to a plant control unit 22. The plant control unit 22 is used to control and monitor the entire production process, from the primary product to the fiber end-product. The sensor means used within the granulate preparation system 1, the melt preparation system 6, the spinning apparatus 10, the treatment device 15 and the winding device 17 for monitoring the production process are not illustrated or explained in greater detailed here. DE 199 11 704 A1, for example, describes a process for the production of a synthetic thread from which a system for monitoring the product and machine parameters is known. To this extent, reference is made to the cited publication.
The plant control unit 22 is connected to a master planning control unit 23 via a data connection 24. The planning control unit 23 has an interface 25 through which an ERP control unit 26 is connected to the planning control unit 23. The ERP control unit 26 serves to map business processes for the purpose, for example, of placing and arranging production orders. Standard PPS software systems can be used in this case.
In the case of the exemplary embodiment of a production process represented in
The actual status of the production process is usually determined on the basis of a partial quantity of fiber product finished per unit of time, since the target standard of the production order is usually predefined in the form of specifications relating to the product quantity or, alternatively, a production time, or through specification for both the product quantity and the production time.
The exemplary embodiments, represented in
Irrespective of the connection to an EPR control unit or an operating unit, the cooperation of the planning control unit with the plant control unit is essential for the monitoring and control of the production orders. For this,
In the case of the exemplary embodiment according to
The differential value is supplied to the planning module 37. The target standards of one or more production orders stored in the planning module 37 are compared in respect of the current differential value, by means of a given planning algorithm, and converted into a processing plan and forwarded. Thus, within an ERP control unit, a proposal can be directly converted into a processing plan, or individual proposals can also be adapted to existing sequences by modifying the target standards of the production orders. Particularly advantageously in this case, the standard for the primary products can be controlled at the same time. Thus, for example, the provision of primary products required in individual production orders could be effected via the processing plan. A high utilization of the machine capacity can be achieved in this way.
In the case of the exemplary embodiment represented in
Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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|U.S. Classification||700/109, 162/263|
|International Classification||D01D5/08, G06F19/00, G01N33/36, D01D13/02, D01D13/00, D21F7/00|
|Cooperative Classification||D01D5/08, D01D13/00, D01D13/02|
|European Classification||D01D5/08, D01D13/02, D01D13/00|
|Aug 22, 2006||AS||Assignment|
Owner name: SAURER GMBH & CO. KG, GERMANY
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:MUHLENMEISTER, REINHARD;GROSS, JORG;SEULEN, DIRK;REEL/FRAME:018153/0833
Effective date: 20060602
|Jul 26, 2012||FPAY||Fee payment|
Year of fee payment: 4
|Jul 25, 2016||FPAY||Fee payment|
Year of fee payment: 8